Fabricated building construction



E w O R C A M F.

FABRICATED BUILDING CONSTRUCTION Filed aan. 11`, 1935 FIE E INVENTOR. /727/76/5 Miko/f77 (ran/e ATTORNEY.

Patented Mar. 31, 1936 UNlTED STATES PATENT oi-Flca FABRICATED BUILDING CONSTRUCTION Francis Malcolm Crowe, Burlingame, Calif.

Application January 11, 1935, Serialy No. 1,280 9 claims. (01.72-16) This invention relates generally to the construction of houses and other buildings, and particularly to the fabrication and erection of the exterior and interior walls thereof. The present application is a continuation in part of my copending Patent No. 1,998,448.

In the aforementioned application is described an arrangement or system of wall construction wherein a variety of standardized panel units may be shop fabricated, upon a quantity production basis, and may be assembled in houses of varied oor plans and of varied architectural appearance, thereby effecting a reduction of cost while retaining a, high degree of individuality. The system reduces to a minimum the number of different types of panel units required, because allunits are structurally interchangeable and are not affected by the necessary installation of` pipes, conduits and the like, nor by the color or texture-of wall finish desired.

A distinguishing feature of the aforementioned system lies in the fact that wall panel units are assembled with spaces intervening between adjacent units, instead of being erected with vertical edges in contact. The panel units utilized each comprise a semi-nished one-piece section of wall, usually one story in height, some of which contain a window, door, or other opening. Adjacent panel units are connected by spacers, the `latter being so arranged that vertical pipes, conduitsY and the like may be installed in the intervening space. Such space also facilitates structural connection of oor joists and other' supplementary framing members to the wall. Subsequently, such joint spaces are covered over or lled, iiush with surfaces of the adjacent panel units, and finally a finish coating or covering may be applied over each wall surface as a. whole. In this way, any objectionable paneled appearance is avoided.

In utilizing such prefabricated or precast wall units, a convenient dimension is selected as the standard distance between centers of successive joint spaces, and all wall units are formed to t o this spacing or a multiple thereof, double or triple width units being required to accommodate thev wider'window and door openings. In preparing the oor plan of a building, if all wall centerlines be located so that the distances between 0 the same are exact multiples of this specified tion is particularly concerned .with the form of the wall units utilized therein, with the arrangement of joints between the same, and with the selection of materials therefor. It is an object of the invention to utilize` durable and preferably fire-resistant materials, but to so simplify the form and arrangement of wall units and'joints 5 that final cost will be at a minimum. Likewise, it is an object to provide moistureproof and insulative characteristics in exterior wall construction.

It is a further object of the invention that'the form and arrangement of wall units and joints shall permit installation of vertical pipes, conduits and the like in spaced joints between panel units without effect upon the latter, that all wall units shall be structurally interchangeable, and that joints may be filled `or covered over flush with surfaces of adjacent panel units so that smooth, unbroken wall surfaces may be provided.

Further objects of the invention will appear from the following description in which the preferred embodiments of the invention have been set forth" in detail in conjunction with the accompanying drawing. It is to be runderstood that the appended claims are to be accorded arange of equivalents consistent with the state of the Referringto the drawing:

Fig. 1 is a side elevation of one form of panel unit utilized in my invention, being of solid Wall type without window or other opening.

along the line 2 2 of Fig. 1.

Fig. 3 is a vertical cross-sectional View taken along the line 3&3 of Fig. 1. Y

Fig. 4 is a diagrammatic horizontal section Fig. 2 is a horizontal cross-sectional view taken 3 showing several panel units aligned on wall cenand incomplete stage of erection.' Fig. 7 is-a similar section through a joint after completion of the wall, and shows certain incidental pipe.V installations. v

Figs. 8 and 9 are horizontal sections, at joints, showing modifications in framing and body structure of wall units, the latter figure also being varied to show a typical T intersection of walls.4

curs, this section being illustrative of an early One very practical form of the invention is shown in Figs. 1, 2 and 3 of the drawing. In this embodiment, the wall unit comprises a rectangular steel frame and a filler slab of aerated concrete or similar material, together with reinforcing steel for'the slab. A moistureproong membrane divides the slab into two layers, and bolts projecting from the frame provide means for making structural connections when erected. Such a unit, designed for exterior walls, may contain a window, door or other opening and, being substantially one-story in height, constitutes a semi-finished, one-piece section of Wall. Obviously, a similar wall unit of lesser height may be provided for basement walls and, conversely, a unit of greater than story height may include a roof parapet wall. In two-story or higher structures, successive tiers of single story wall units will,usua1ly be preferable'to double story units.

In the standard wall unit shown in Fig. 1, the rectangular steel frame consists of vertical members Il, and top and bottom horizontal members I2 and I3. Such frames usually will be shop assembled with welded corner connections, although corner gusset plates or clip angles with riveted connections may be substituted. The vertical members I I consist of steel channels, being either standard rolled sections or lighter pressed sections. Such channels are positioned with flanges toeing inward so as to engage the filler slab. Top and bottom members are of male and female sections so as to nest perfectly, forming tight horizontal joints. Thus the top member may be an angle, or a Z section, as shown, with a vertical leg near the inner face of the frame, this leg toeing upward to serve as flashing. The bottom member I3 can be a round-backed angle section, arranged to nest inside the top member of a lower tier of wall units, as shown in Fig. 5, and also to nest in a sill angle I4 which may occur at the top of a foundation wall, as also shown in this sectional view of an erected wall. The top and bottom members I2 and I3 may be of either rolled or pressed steel sections and can be of light weight as they are not stressed structurally.

The body I5 of the wall unit can be formed of a substantially solid or laminated slab of aerated concrete or of any similar material thail pos'- sesses insulative properties and that will be unaffected by moisture. The slab thickness is greater than the depth of the panel frame, as is shown in Fig. 2 by comparison of the dimensions t and d respectively. Therefore, the plane of each slab surface passes wholly outside of the panel framing members, with shoulder offsets occurring y along the toa edges of framing channels I I. This feature is of importance since it allows subsequent enclosure of the framing members wholly within the finished wall. A

Where the body slab I5 of wall units is composed of a material that is not impervious to moisture penetration, it is desirable to incorporate a waterproofing membrane into the slab. Thus, using aerated concrete, or a similar material, the panel frame may be laid horizontally on a flat form, the latter tted with lips to form the shoulder offsets previously described, and with the frame serving as a form around slab edges. About one-half `thickness of the body ller slab is then poured, denoted by numeral lia in Figs. 2 and 3. When this layer has set, a coating of asphalt, emulsifled asphalt or other waterproong material is applied to the top sur- 75 face thereof to serve as a moistureproong mem- 'tween adjacent wall units. When the membrane construction previously described is adopted, such reinforcement may occur in separate layers I'Iaand I'lb (Figs. 2 and 3) to reinforce each layer of the slab. Metal ties I8 (Fig. 3) can be provided to bond the two slab layers together. The reinforcing steel can be tack Welded to the framing members to prevent movement of the latter with respect to the filler slab. Such Welds should be placed near the toes ofv the flanges of the channels II, so that reinforcement extending past such flanges may be bent slightly out and away from contact therewith, permitting such reinforcement to be wholly embedded in material to be placed subsequently at joints.

When bolted connections are desired for erection procedure, in preference to welding on the job, provision therefor must be made during fabrication of the wall units. 'I'his may be done, prior to pouring the ller slab, by inserting bolts I9 (Fig. 1) through holes punched in framing channels II. These bolts project outwardly at proper locations for top and bottom connections, for intermediate' spacers, and for supplementary structural framing at floor and ceiling levels.

It should be noted that standard wall units, as hereinabove described, may be completely shop fabricated, including precasting of the filler slab and installation, in some types, of a window or door. Such wall units require, after erection, only surface nish treatment.

As previously mentioned, and as described in detail in the aforementioned co-pending application, my wall units are intended primarily for erection with spaced joints occurring at regular intervals. Several such wall units are shown in Fig. 4, aligned on intersecting wall center-lines. The distance from center to center of joint spaces, denoted by dimension S thereon, usually will be the predetermined dimensional increment or a multiple thereof. Clearance lines c-c and cl-cl have been drawn through joint centers at 45 with respect to wall center-lines. It will be noted that no rigid portion oi the wall unit extends beyond such clearance lines. Thus, wall units are structurally interchangeable and can be used at intermediate locations in a straight wall, adjacent to a corner intersection as in Fig. 4, or adjacent to a T intersection, as in Fig. 9. While projecting portions of slab reinforcing steel may extend beyond the 45 clearance lines, such reinforcement is comparatively flexible and will not interfere with so positioning the wall units. Of course, standard wall units, devoid of bolts projecting from channel webs, can be erected with'vertical members in contact and will retain the advantage of flush type joint nish. In this case, structural connection of adjacent panel units will be by welding or by plates connecting abutting anges of adjacent channels, and piping must be installed elsewhere.

The preferred type of spaced joint, occurring between wall units of the type described, is shown in section in Figs. 6 and 7. Adjacent wall units are erected with a predetermined distance intervening between their opposed vertical framing members Inl, and are rigidly connected by pairs oi clip angles 2li, the latter being of short length and occurring 'at top, bottom and certain intermediate points along the framing members, using the bolts `i9 provided for this purpose. Where welded connections are adopted forerectio'n, the spacers may consist of short lengths of channel section. In either event, it .should-be noted that the space between wall units is substantially unobstructed at the stage of erection indicated in After erecting the wall units and Supplementary structural framing, including door and roof beams and the like, the necessary plumbing and wiring should be installed, with all vertical pipes, conduits, wail outlet boxes and the like locatedin joint spaces, as indicated by numeral 2i in Fig. 7. Such spaces usually will accommodate all vertical piping. with the possible exception of large diameter soil pipe or heating ducts.

Joints between wall units, where the latter embody an aerated concrete i'lller slab of membrane construction, will be inished as shown in Fig. '7. A waterproong membrane 22 is installed across the joint space, such membrane being of sheet metal or waterproof paper and being at, or, as indicated, with crimped corrugations. The joint space remaining on each side of this membrane is then lled with aeratedooncrete 23a and 23h poured on the job, the outer surfaces of such till being ilush with surfaces of adjacent wall unit slabs. The joint membrane can be installed in short lengths so that small at forms can be placed across each side of thejoint, bearing against adjacent wall unit slabs, the filling of each joint space therefore being performed in several lifts. It will be noted that projecting ends of wall unit slab reinforcement serve to reand after troweling in similar material at horizontal joints, smooth wall surfaces are provided, unbroken by any oiiset, depression or opening. To iinish the wall requires only an application of surface coating or covering. Exterior nish 24 in Fig. 'l may be a thin coating of stucco, gunite, cement paint or similar material, the thickness of which need be sufllcient only to give the desired color and texture of finish. Such coatings bond perfectly onthe aerated concrete slab surfaces, and no extra thickness of finish need be applied for waterproo'fness since this feature is cared for by the membrane construction of the wall itself. Similarly. interior wall finish 25 can consist of a minimum/thickness of plaster, plastic paint, wall paper, or similar coating.

Considering now thejalternative embodiments of this invention, it should'be noted first that the i'lller slabs and joint lls may becomposed of any light-weight concrete possessing adequate insulative properties. In addition to aerated concrete, for which several processes of manufacture are available, concrete made with pumice, Haydite, rice hulls, wood bark or fiber or other light-weight coarse aggregates can be used in the construction as hereinabove described. Likewise, various so-called composition materials may prove to be practicable in the solid slab design. Obviously, if such composition slab be waterproof, then the moistureproong membrane may be omitted.

Many modications in the form of wall unit are framing members. For example, as shown iny Fig. 8. the vertical members may be of a pressed steel channel section 26 having a concave web. -Such a section is advantageous where welded erection connections are adopted, in which event spacers will consist of short lengths oi pipe, the outside diameter of which matches the curvature of the concave web so that the connection will be self-aligning. Another alternative is shown in Fig. 9, in whih the framing members are in the form of a special rolled steel channel section 21 having an outstanding leg 28 to which bolted connections may be. made, thus eliminating need for-'the projecting bolts i9. In this case, spacers can' be flatplates or may be a continuous plate serving also as joint membrane. 'Either of these two and other alternatives may be substituted in the Wall unit described, without other modification. Similarly. .many alternative pairs of male and female sections are available for use as top and bottom framing members.

An alternative moistureproofing membrane for the solid type of wall unit iiller slab is shown in the lower wall unit in Fig. 5. This consists of a sheet 29 of waterproof paper or metal having crimped corrugations, as shown, so that the two slab layers are interlocked, thereby eliminating need for the ties it previously described. Of course, at sheets of waterproof paper or metal also may be substituted for the membraneV coating aforementioned.

" Solid slab construction of -wall units is not limited to use of a single homogeneous material, one alternative being to fill the wall unit frame successively with three or more laxninations. Thus, with` the frame placed upon a horizontal form as previously described, a layerof dense concrete may be poured iirst to form one slab surfacing layer, then a layer of light-weight insulating material, and inally` the other concretesurfacing layer. In this. alternative, wire mesh reinforcement can be provided for the surfacing layers, as well as cross ties similar to those lpreviously described. The outer layer should be moistureproof or be backed by a membrane coating or sheet. Such construction is indicated in the upper ,wall unit 30, shown in Fig. 5, wherein the body is formed of layers 30a, 30h and ttc. with the intervening membrane Si.-

Prior reference has been made to the use of ller slabs containing hollow, inaccessible cores, and such construction is illustratedl in the'wall units shown in Fig. 8. Such interior spaces t2 `may be formed by stiff paper form cells positionedrin the lpanel frame prior to pouring the slab; by deferring the assembly of one member of the rectangular frame until after the slab has been cast and the core forms withdrawn; by assembling the frame around apreviously formed slab; or by precasting the .slab in half layers which are locked together by framing channel flanges after assembly of the frame. In,

the latter alternative, an aluminum foil membrane may Ibe installed between such half slabs, serving both insulating and moistureprooflng purposes.

Relative to joint spaces, an alternative method of, completing the Wall is shown inv Fig. 8. In this case, cover tiles 33 are placed across the joint opening, the thickness of such tiles being equal to the shoulder offsets to the wall unit surfaces.

'Ihese tiles may be backed by sheet metal or l paper 34 to prevent moisture penetration. Interiors of joint spaces sb covered may be left hollow or may be filled with loose insulating material. A second alternative, similar in result,

j involves the provision of projecting wire fabric V struction as well as to exterior walls. There being no risk of moisture penetration, interior walls do not require the inclusion of a membrane, either in wall units or across joint spaces. Selection of materials for interior use may include gypsum and other alternatives in addition to those aforementioned. As shown in Fig. 9, when using a monolithic filler slab 35, the reinforcement may be concentrated in one layer 36, and the projecting reinforcement at the slab shoulder offsets may be strips of wire fabric or metal lath 31. Furthermore, top and bottom framing members of the interior Wall units usually will consist of channels, rather than the sections previously described, and will not necessarily be of male and female type, since such units may rest upon oor beams instead of upon a continuous foundation.

In conclusion, it should be noted that the inner face of the exterior wall units and both'faces of the interior bearing wall units may be formed with shoulders 38 and 39 (Fig. 5) at the levels of floor deck 40 and ceiling slab 4|. In Fig. 5 supplementary steel framing is also indicated, there being shelf angles 42 and 43 shown at both floor deck and ceiling slab levels. It will be observed from Figs. 6, 7, 8 and 9 that opposed pairs of vertical framing members in adjacent Wall units, rigidly connected by spacers, constitute structural columns at each joint space. Thus such columns, together with floor and roof beams, shelf angles and bracing, constitute a steel framed structure which may be fully as rigid and equally as strong as any steel framed structure assembled of separate framing members by conventional methods. However, in sheathing the frame, in providing the complete building, great simplification has been achieved through panel type construction. The saving in cost of fabrication and erection appears to be more than ample to offset the higher basic cost of the superior materials used, so that my invention makes possible not merely better but actually cheaper houses.

I claim:

1. In a building construction, a prefabricated panel unit for walls, comprising members forming a rectangular frame, and a rigid body filling the space within said frame, the thickness between the surfaces of said body being greater than the depth of the members comprising the rectangular frame, shoulder offsets occurring along the juncture of said framing members with the body, thereby permitting the subsequent application of material to cover the exposed portion of said marginal framing members and allowing the outer surface of said covering material to be flush with surfaces of the body portion of the panel unit.

2. In a building construction, a prefabricated panel unit for walls, comprising members forming a rectangular frame, and a rigid body filling the space within said frame, the thickness between the surfaces of said body being greater than the depth of the members comprising the rectangular frame. shoulder offsets occurring along the juncture of said framing members with the body, thereby permitting the subsequent application of material to cover the exposed portion of said marginal framing members and allowing the outer surface of said covering material to be ilush with surfaces of the body portion of the panel unit, said rigid body being formed of cementitious material and containing metallic reinforcement extending through said body between opposite members of the frame and attached thereto, metallic reinforcement extending outwardly from the interior of said body through the shoulder offsets therein, such projecting reinforcement to serve subsequently to bond the covering material to be applied at the joint between two such panel units.

3. In a building construction, a prefabricated panel unit for walls, comprising members forming a rectangular frame, and a rigid body lling the space within said frame, the thickness between the surfaces of said body being greater than the depth of the members comprising the rectangular frame, shoulder offsets occurring along the juncture of said framing members with vthe body, thereby permitting the subsequent application of material to cover the exposed portion of said marginal framing members and allowing the outer surface of said covering material to be flush with the surfaces of the body portion of the panel unit, said rigid body formed of two layers of cementitious material, metallic reinforcement for said cementitious material, a moistureproof membrane between said layers, and means for securing said layers together.

4. In a building construction, a prefabricated panel unit for walls, comprising members forming a rectangular frame, and a rigid body filling the space within said frame, the thickness between the surfaces of said body being greater than the depth of the members comprising the rectangular frame, shoulder offsets occurring along the juncture of said framing members with the body, thereby permitting the subsequent application of material to cover the exposed portion of said marginal framing members and allowing the outer surface of said covering material to be flush with the surfaces of the body portion of the panel unit, said rectangular frame being of metal,.the vertical members thereof being channels positioned with flanges toeing inwardly toward the interior ofthe frame to engage the body filling the space therein.

5. In a building construction, a plurality of vertical prefabricated panel units aligned on a wall center-line, said panel units each comprising members forming a rectangular metallicframe, anda body composed of cementitious material filling the space within said frame, the` frame forming a margin for the body, the thickness between surfaces of said body being greater than the depth of said frame so that shoulder offsets occur along the juncture of said marginal frame with the body, metallic reinforcement extending through said body and attached to opposite side members of the frame and metallic reinforcement projecting outwardly from said body through said shoulder offsets, means for connecting the opposed`vertical members of the frames of adjacent panel units,the projecting reinforcement from adjacent panel units overlapping at joints between said units, and cementitious material applied upon said exposed reinforcement, the thickness of said material being suficient to provide outer surfaces which complete the continuity of wall surfaces established by body portions of the aligned panel units.

6. In a building construction, a plurality of vertical prefabricated panel units aligned on a wall center-line, said panel units each comprising members forming a rectangular metallic frame substantially one story in height, and a rigid body filling the space within said frame, said body being formed of two layers of aerated concrete with a moistureproof membrane between said layers and with metallic reinforcement extending through the body between opposite members of the frame and-attached thereto `and continuing to project outwardly through shoulder offsets, said shoulder offsets occurring at the juncture of vertical members of the frame with the body, the thickness of said body being greater than the depth of said frame members; said panel units being so positioned that space intervenes between the opposed vertical frame members of adjacent panel units, metallic spacers connecting said pairs of opposed vertical members, the spacers being arranged so as to permit installation of vertical pipes and the like within the space between adjacent panel units, a moistureproof membrane extending across the interior of said space between adjacent panel units, and aerated concrete filling the remainder of said space on each side of the joint space membrane, embedding reinforcement projecting from adjacent panel units, the surfaces of said joint ll being flush with the body surfaces of the panel units adjacent thereto.

7. In a building construction, a plurality of vertical prefabricated panel units aligned on a wall center-line, said panel units each comprising a rectangular frame and a body filling the space within said frame, the thickness between the surfaces of said body being greater than the depth of members comprising the rectangular frame so that a shoulder offset to one outer surface of the body occurs along the juncture of said framing members with the body, the opposed vertical members of frames of adjacent panel units connected in pairs to form a structural load supporting column within the wall,

established by surfaces of body portions of adjacent aligned panel units, thereby completing the continuity of a wall surface.

8. In a building construction, a plurality of vertical prefabricated panel units aligned on a wall center-line, said panel units each comprising members forming a rectangular frame substantially one-story in height and a body filling the space within said frame, the thickness between outer surfaces of said body being greater than the depth of members comprising the rec-- tangular frame so that shoulder 'offsets occur along the juncture of said framing members with the body and so that outer surface planes of said body lie outside of lateral edges of framing members, said panel units being so positioned that a space intervenes between the opposed vertical members of frames of adjacent panel units, spacers connecting pairs of said opposed vertical framing members to form load supporting structural columns within the wall, said spacers being arranged so as to permit installation of vertical pipes and the like within the joint spaces between adjacent panel units, and means for completing the continuity of wall surfaces established by the outer surfaces of body portions of aligned panel units, said means extending between opposed shoulder offsets of adjacent panel units and concealing the joint space, the exposed portions of frame members and any pipe installed within said joint space.

9. In a building construction, a prefabricated panel unit for walls comprising members forming a. rectangular frame and a rigid body filling the space within said frame, the thickness between outer surfaces of said body being greater than the depth of members comprisingathe rectangular frame, shoulder offsets occurring along the juncture of said framing members with the body, thereby permitting the subsequent application of material to cover the exposed portion of lsaid marginal framing members and allowing 'the outer surface of said covering material to be flushl with outer surfaces of the body portion of the panel unit, said rigid body being formed of two layers of material, each layer being formed inwardly around its periphery so that the said two layers meet in contact near and engage the inner face of marginal framing members, thereby enclosing a hollow interior within said rigid body.

FRANCIS MALCOLM CROWE. 

